Technical X250 central locking 'squealing/gratting' noise

[gm6vxb]

Van is a 2007 X250 with motorhome body.
Yesterday was walking past the van and noticed a strange squealing noise coming from around the passenger door area. Did some checks and it appears to be due to the central locking.
From inside the van, the noise appears to be coming from both driver and passenger doors, so suspicion is the lock actuator(s) are being driven all the time or are not going fully into the lock/unlock position if there is a 'tellback' on the solenoids (I suspect no tellback though).
Yesterday the van would both lock and unlock from the key fob, and from the buttons on the dash, but today operation has become more intermittent with both lock and unlock not always working and always accompanied by the squealing. Presently default seems to be 'doors locked'.
Removing fuse F36 (Central door locking) stops the noises but doors remain locked, fortunately a side door to access though.
I have read elsewhere that there might be a control module for the central locking, if there is, where is it located ?.
It's pretty cold and rain/snow forecast for tomorrow so taking the door apart to see whats going on will have to wait for some slightly better weather.
Will do more checks and reading up but would appreciate any help.

Martin, GM6VXB

 

[gm6vxb]

Checks this morning after leaving fuse F36 out all night and the doors lock and unlock from both the key fob and switches on dashboard. Do not believe it so will be locking/unlocking doors every hour or so until boredom gets me !.
Did some checking last night and found a diagram showing the door lock electrical schematic (for front doors only) and it appears I was wrong and there is a 'Tellback' for the lock actuator solenoids. When it warms up I will strip the door down to check if this is correct or not as I am not beleiving the manual.
As for the location of the 'Door management control unit the manual says (section 7.4) that the module is located under the dashboard on the right hand side. Unless it is behind the fuse box I can see no sign of it. Will do somemore checks using an Endoscope though.
Fingers crossed this was just another one of the wierd faults I have had with the Ducato.

Martin, GM6VXB

 

[Anthony489]

Hi Martin

A while back I took out the front door cards to fit soundproofing. Here are my notes in case it helps:

Ducato X250 Door Card Removal

Set window open or closed as desired.

Take off lower storage bin, 4 x Torx. Don’t lose the metal collars. Set aside.

Pry up rear edge of window switch, remove connector (tab) and set aside.

Pry off speaker grille and set aside

Remove speaker, 3 x Pozi plus connector and set aside carefully

Pry off rear edge of top rear “corner panel”, and hinge up for bolt access.

Pry out lower edge of small panel behind door pull.

Remove all Torx bolts and 2 lower Pozi screws from grey plastic upper handle moulding, then swing up out of the way. Anchor with a bungee. Leave Bowden cable attached.

Remove hardboard door card by levering white plastic barbs out of yellow plastic sockets in door. If the barbs come out of the panel they can be put back (half turn into rectangular hole) but this is best avoided.

Remove waterproof foamy plastic door skin by very carefully peeling jelly adhesive and cutting along its centre with a chisel or sharp Stanley knife, using a sawing action as you pull. This allows re-use.

 

[gm6vxb]

Checks this morning after leaving fuse F36 out all night and the doors lock and unlock from both the key fob and switches on dashboard. Do not believe it so will be locking/unlocking doors every hour or so until boredom gets me !.
Did some checking last night and found a diagram showing the door lock electrical schematic (for front doors only) and it appears I was wrong and there is a 'Tellback' for the lock actuator solenoids. When it warms up I will strip the door down to check if this is correct or not as I am not beleiving the manual.
As for the location of the 'Door management control unit the manual says (section 7.4) that the module is located under the dashboard on the right hand side. Unless it is behind the fuse box I can see no sign of it. Will do somemore checks using an Endoscope though.
Fingers crossed this was just another one of the wierd faults I have had with the Ducato.

Martin, GM6VXB

Managed to do a bit more checking this morning and found the Door management module (0134-596-**-80).
For those interested, on a right had drive van the module is located under a plastic panel at the bulkhead end of the footwell. Panel is held in with one 'Phillips' type and two 'twist on' devices.
Suprised to find there is water in the connector which could explain the problem. How you get water there I do not know !.
Drying out connectors now but suspect this was the problem.
Might get it re-fitted before todays rain starts.

Martin, GM6VXB

 

[gm6vxb]

Just a bit more information and help needed.
The problem with door locking (and noise from the servo's) is definately associated with the CGP body control unit 134-596-40-80.
Have dried out the unit but a couple of the connectors were quite corroded but still intact. Due to the design of the unit it is not easy to clean the contacts effectively. Looking at the plug it seems to be ok but could do with the contacts being 'adjusted' which might tighten them a bit.

Have had no problems with locking/unlocking doors for a few weeks but now am back to square one with the doors failing either locked or unlocked and only getting correct operation when I disconnect/connect the module.

There appear to be four variations of the CGP module but can find little information on the differences but suspect there might be more relays to control more doors or dead locks than my van has.

I have looked to see if I can get another CGP unit but the only one I have found is a different type number (134-596-20-80) from Germany.
I suspect that there is a difference in the internals so might not not work correctly.

For info the CGP module only controls the two front doors on the van.

Breakers are few and far between up here (North Aberdeenshire) so might struggle finding a used but good replacement.

So how similar is the 134-596-40-80 to the 134-596-20-80 unit and can they be swapped ?.

Martin, GM6VXB

 

[Anthony489]

Hi Martin

This module (M080) sits between the BCM and the motors in the cab door locks.

I think CGP are probably the Italian manufacturer. Not much information on their products.

The 134-596-20-80 gets various web listings as a Fan Control Relay, Glow Plug Relay and Fuel Pump Relay, which rather tends to suggest it is has a single high current relay inside. It probably also has some simple driver electronics to go between the logic command input and the relay coil itself. Not terribly high tech.

The 134-596-40-80 is similar, but is likely to have at least two relays inside (one for each door)

As is often the case, this is educated guesswork !

Is it possible to take the case apart (in a non-destructive way) in order to clean/dry it out more thoroughly ?

 

[gm6vxb]

Hi Anthony,

I am at the same conclusion as yourself, a 20-80 module having one relay, and the 40-80 having two.
How many relays in the other two units is a guess but probably three then four.

Have taken my 40-80 apart, cover just held by small plastic clips, and made sure the internals were dry
which initially they were not. Had the board on a heater twice now but second time more as a 'just in case'
precaution as the board looked dry.

The 40-80 has two small (5 Ampere ?) relays and a few other components so maybe a multi layer board
with components hidden internally but difficult to be certain
.
So far can only find the 20-80 unit online but also trying local'ish Breakers but no replies so far.
Did phone the nearest FIAT place in Aberdeen but they were no help saying the unit is obsolete. We do have
an IVECO dealer not too far away so will try them later but suspect they will not be able to help as the module
is a body part rather than engine.

Will do more on I'net later today to see if anyone has a module.

 

[gm6vxb]

Fianlly got to the back of the locking problem except for how water gets into the CGP door lock module.
Ended up with the doors refusing to lock. Unlock audibly did what was expected but doors were unlocked anyway.

After a lot of 'faffing about' it turns out the problem was one of the relays in the CGP module had failed (two fitted, one for each front door in my case). Relay fitted is an OMRON G8N type which are difficult to find in the UK. Do not know why they use such a high current relay as the door locks only draw around two ampere for less than two seconds. The OMRON is capable of switching up to thirty ampere !.

So, 'cobbled' a five ampere relay into the module and it works fine. Not a final fix as will look around local scrappers to see if I can find another CGP module.
Just for info, there are four different CGP modules:
134-596-40-80 (marked L1) is for two doors only, which is the one fitted to my Lunar (Homecar) motorhome.
134-596-30-80 (marked L2) is for two doors plus deadlock
134-596-20-80 (marked L3) is for two front doors plus side door. Probably fitted to a lot of motorhomes.
134-068-00-80 (marked L4) can work four doors, so probably fitted to most vans/ van conversions.

Also managed to lock up the passenger side door lock (was pretty rusty inside anyway), so had to replace this as well. Found several different part numbers for these but they are nearly all identical to one fitted on my van. Went for a second hand unit from a 2007 van. Taking the door apart to get to the lock was a pain, but putting back together dead easy. Not a job to do if you have high blood pressure !!.

Now just got to figure the initial water on pin 14 of the CGP module. All wiring is internal, cabling to either door, or to the fuse box. So could be a tricky one to figure out.

Martin, GM6VXB